Disassemble

Gears & Shaft Components. Toyo Kogyo 5 Speed Overdrive Manual Transmission:

1. Drain transmission lubricant, then remove fork and release bearing from transmission case.
2. Remove 6 front cover attaching bolts, then the front cover, shim and gasket.

Front Cover Oil Seal Removal:

3. Remove front cover oil seal, then the input shaft snap ring.
4. Remove gearshift lever, if installed. Remove 4 gearshift lever retainer attaching bolts, then the retainer and gasket from extension housing.
5. Remove outer snap ring from input shaft bearing.

Input Shaft Bearing Removal Tool Installation:

Input Shaft Bearing Removal:

6. Remove input shaft bearing.
7. Remove 8 extension housing-to-transmission case attaching bolts, then slide housing off output shaft with control lever end laid down and to the left as far as possible.
8. Remove control lever end attaching bolt, then the control lever end and rod from extension housing.
9. Remove speedometer driven gear assembly from extension housing.
10. Remove back-up lamp and neutral sensing switches from extension housing.
11. Remove grommet from end of output shaft, then the speedometer drive gear snap ring, speedometer drive gear and lock ball.

Countershaft & Front Bearing Removal:

12. Remove countershaft with front bearing, from transmission case.
13. Remove and discard 1st-2nd shift fork roll pin and shift rail snap ring.

Shift Lock Ball & Spring Removal:

14. Remove upper cap bolt, spring and detent ball, then the 1st-2nd shift rail and fork. Note position of shift fork, rail and detent slots for assembly reference.
15. Remove and discard 3rd-4th shift fork roll pin and shift rail snap ring.
16. Remove middle cap bolt, spring and detent ball, then the 3rd-4th shift fork, rail and interlock pin. Note position of shift rail and detent slots for assembly reference.
17. Remove 5th-reverse shift rail snap ring and washer, then the lower cap bolt and outer spring and detent ball.
18. Remove 5th-reverse shift fork roll pin, then the inner detent ball and spring from lower bore.
19. Pry intermediate housing away from bearing housing, then remove gear and bearing assembly from the intermediate housing.
20. Secure gear train and bearing housing assembly in a suitable soft-jawed vise, then remove 5th-reverse shift rail and interlock pin. Note position of shift fork, rail and detent slots for assembly reference.

Output Shaft Rear Bearing Removal:

21. Remove and discard output shaft rear bearing.

NOTE: It may be necessary to hold shaft protectors in place with putty when removing bearing.

Countershaft Rear Bearing Removal:

22. Remove countershaft rear bearing snap ring, then remove and discard the bearing.
23. Remove retaining ring, thrust washer and lock ball from output shaft.
24. Remove counter 5th gear, sleeve and reverse gear from countershaft.
25. Remove 5th gear and 5th-reverse synchronizer ring from output shaft.

Mainshaft Locknut Removal & Installation:

26. Bend down tab on mainshaft lockwasher, then lock transmission into reverse and any forward gear and remove and discard output shaft (mainshaft) locknut.
27. Remove 5th-reverse synchronizer assembly, reverse gear, caged needle bearing, sleeve and thrust washer from output shaft.
28. Remove snap ring, reverse idler gear and keyed thrust washer from idler shaft.
29. Remove 5 bearing cover attaching bolts and the cover.
30. Remove idler shaft attaching bolt, then drive plate and shaft assembly out of bearing housing.
31. Tap output shaft and countershaft out of bearing housing using a suitable hammer.
32. Separate input shaft, caged needle bearing and synchronizer from output shaft.
33. Remove rear countershaft bearing from bearing housing using tool No. T77J-7025-B or equivalent.
34. Remove rear output shaft bearing from bearing housing using tools T77F-4222-A and T77J-7025-B or equivalents.

Exploded View Of Shafts & Gears:

35. Remove thrust washer, 1st gear, sleeve and synchronizer ring from rear of output shaft.
36. Remove 3rd-4th hub, sleeve, synchronizer ring and 3rd gear from front of output shaft using a suitable press and tool No. T71P-4621-B or equivalent.
37. Remove 1st-2nd hub, sleeve, synchronizer ring and 2nd gear from rear of output shaft using a suitable press and tool No. T71P-4621-B or equivalent.

Countershaft Front Bearing Removal:

38. Press front bearing out of countershaft.